Caterpillar Inc. – Mapleton Foundry
Mapleton, Illinois
Intern: Sajana Chitrakar
Bradley University, Peoria
Caterpillar’s Mapleton Foundry, also known as the Cast Metals
Organization, is a gray iron foundry. It is the only foundry solely owned
by Caterpillar Inc. and casts engine blocks, engine heads and cylinder
liners. The facility operates 24/7 and employs approximately 850 people.
The intern student conducted a facility-wide energy audit at the foundry.
Anticipated Results:
The following recommendations were made to:
- Replace existing metal halide lamps with high efficiency sodium
lamps. This project has the potential to save the facility over $300,000
a year.
- Use synthetic lubricants in the air compressors and implement a
program to detect and reduce air leaks. This could result in a savings
of $64,000 a year.
- Turn off lights in unoccupied areas and install occupancy sensors.
This has the potential to save $28,000 a year.
- Install high efficiency motors when old motors are due for replacement.
This could save up to $21,000 a year.
- Replace standard V-belts with cogged belts. This has the potential
to save $8,800 a year.
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